Conjugated Stretch Yarn, Gloves and Stretch Fabric with Openwork Pattern

ABSTRACT

A composite elastic yarn includes a polyolefin-based elastic fiber and a polyolefin-based inelastic fiber. A cross-linked polyolefin-based elastic fiber, for example, is employed as the polyolefin-based elastic fiber, and a high molecular-weight polyethylene fiber having a weight average molecular weight of at least 10×10 5 , for example, is employed as the polyolefin-based inelastic fiber. Such a composite elastic yarn is suitable for use as a glove material. The yarn may be used to produce a stretchable fabric with a watermark-like pattern including a cross-linked polyeolefin-based elastic fiber and an inelastic fiber, and having a watermark-like pattern produced by complete or incomplete removal of the inelastic fiber with partial burn-out printing.

REFERENCE TO RELATED APPLICATIONS

This is a national stage application under 35 USC 371 of InternationalApplication No. PCT/JP2005/015712, filed Aug. 30, 2005, which claimspriority from Japanese Patent Application Nos. 2004-256844 and2004-343995, filed Sep. 3, 2004, and Nov. 29, 2004, respectively, theentire disclosures of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a composite elastic yarn with excellentchemical resistance and lightfastness, suitable for application toobjects where durability is required, such as swimsuits, underwear,outerwear, diaper covers, sanitary products, outdoor products liketents, and industrial materials.

The present invention further relates to a cut-resistant glove which hasexcellent chemical resistance, lightfastness, and quick-dryingproperties, and is suitably used when handling iron plates with sharpedges or burrs; dealing with glass; engaging in dangerous work usingknives, such as the processing of meat and cutting of large fish; andthe like.

The present invention also relates to a stretchable fabric with awatermark-like pattern having high stretchability, and a manufacturingmethod therefor.

BACKGROUND OF THE INVENTION

Composite elastic yarns are widely used in swimsuits, leotards,underwear, outerwear, diaper covers, stretchable parts of sanitaryproducts, tent sheets and the like. Conventional composite elastic yarnsare covered yarns wherein a general-purpose inelastic filament yarn,such as those made of polyester or polyamide, covers a polyurethaneelastic core yarn.

Although polyurethane elastic fibers have high stretchability, theirchemical resistance and weatherability are significantly inferiorcompared with general-purpose yarns. For this reason, sufficientdurability cannot be achieved when polyurethane elastic fibers are usedin garments which are to be subjected to industrial cleaning involvingchlorine sterilization; in swimming suits; and in materials which areexposed outdoors, such as car sheets. In order to improve chemicalresistance and weather resistance of polyurethane elastic yarns,attempts at adding various additive agents thereto have been made.However, the nature of polyurethane elastic yarns remains substantiallyunchanged, and such polyurethane elastic yarns cannot be used especiallyunder severe conditions (see, for example, patent document 1 and patentdocument 2).

Polyester fibers and polyamide fibers, which are used as inelasticfibers in composite elastic yarns, have chemical resistance andweatherability superior to those of polyurethane elastic fibers.However, these fibers are inappropriate for use as a material that isexposed to harsh environments, such as prolonged outdoor exposure orindustrial cleaning with chlorine or other chemicals, because theyhydrolyze and/or turn yellow under such conditions.

An example of a suitable application for composite elastic yarns is useas a glove material. Excellent cut resistance is required in gloveswhich are used when handling iron plates with sharp edges or burrs;dealing with glass; and engaging in dangerous work using edged toolssuch as knives, including the processing of meat and cutting of largefish. Known cut-resistant gloves are those made from yarns of aramidfibers, metal fibers, glass fibers, and the like. However, the use ofgloves made of metal fiber yarns is limited due to the poor flexibilityof metal fiber yarns and resulting difficulties in knitting, and alsodue to the electrically conductive nature thereof. Glass fibers maybreak in a glove, and the broken ends of the fibers occasionally projectfrom the inner surface of the glove and stick into the hand. Aramidfibers are prone to lose their strength by contact with strong acid orstrong alkali, and further, if exposed to natural light, the fibers arediscolored and/or their abrasion resistance is decreased.

High-tenacity polyethylene fibers are also employed as cut-resistantglove materials. Although high-tenacity polyethylene fibers do notexhibit the above-described defects, because these fibers are poor instretchability, the stretchability of the knitted fabric of a gloveobtained therefrom is imparted only by its knitting structure.Stretchability of the glove is thus occasionally insufficient for someuses; the glove cannot be easily put on or taken off, and also, theadherence thereof to the skin may be inadequate.

Composite yeans comprising a polyurethane elastic yarn as a core yarnhave been developed in an attempt to improve the stretchability ofhigh-tenacity polyethylene fibers. However, as mentioned above, thechemical resistance and weatherability of polyurethane elastic yarns arefar worse than those of general-purpose yarns. When a glove is made thinand light using such a high-tenacity polyethylene fiber so as to enhancewearing comfort, the exposure of the core yarn, composed of apolyurethane elastic fiber, becomes great. As a result, the adversecharacteristics of polyurethane elastic fibers as described abovesignificantly degrade the physical properties of the glove.

Quick-drying properties are required in gloves for use in activitiesusing water and in outdoor leisure activities, because wet gloves give astrong feeling of discomfort to the wearer and also undermineworkability. However, conventional gloves do not possess a quick-dryingnature.

As described above, a cut-resistant glove which provides a comfortablefit and has excellent chemical resistance, weatherability, andquick-drying properties has not yet been achieved.

In recent years, there has been a high demand for designs on underwear,swimsuits and the like, and it has been accordingly desired to applyburn-out printing to stretchable fabrics from which these products aremade.

A well-known example of a burn-out printing method is opal finishing.Opal finishing is a method wherein a fabric is first obtained as a unionfabric or union knit containing an acid-resistant fiber, such as silkfibers, polyamid-based fibers and polyester-based fibers, and avegetable fiber which is easily carbonized by acid, such as cottonfibers and rayon fibers. The obtained fabric is then printed with acarbonizing paste made of sulfuric acid, aluminium sulfate or the like,and the vegetable fiber at the printed portion is then carbonized andaccordingly removed, thereby forming a watermark-like pattern. Accordingto one conventional technique of this method, for example, an unionfabric or union knit is made by weaving or knitting a polyester-basedfiber having relatively high acid resistance with a cellulose fiberhaving poor acid resistance, the fabric or knit thus obtained isprocessed with acid, and the cellulose fiber is thereby burnt out,resulting in the formation of a watermark-like design on the fabric(patent document 3). Another opal finishing method is known for giving awatermark-like pattern to a fabric made of different kinds of polyesterfibers having different degrees of alkali solubility (patent document4).

As mentioned above, as materials for stretchable fabrics, covered yarnsare widely used which are obtained by covering a polyurethane elasticcore yarn with a general-purpose inelastic filament yarn made ofpolyester, polyamide or the like. However, watermark-like patternformation by opal finishing is not possible on such a fabric because, aswith the above-described general-purpose inelastic filament yarns,polyurethane elastic fibers have poor acid resistance. Moreover,polyurethane fibers easily turn yellow and thus are not suitable asmaterials for fabrics on which to form a watermark-like pattern.

-   -   [Patent document 1] JP 2001-081632 A    -   [Patent document 2] JP 1994-081215 A    -   [Patent document 3] JP 2002-61070 A    -   [Patent document 4] JP 1993-263375 A

SUMMARY OF THE INVENTION

The present invention aims to solve the above-described problems. Thefirst object of the invention is to provide a composite elastic yarnwith excellent chemical resistance and weather resistance.

The second object of the invention is to provide a cut-resistant glovewith high resistance to chemicals and weathering.

The third object of the invention is to provide a stretchable fabricwith a watermark-like pattern, and a manufacturing method therefor.

[Means for Solving the Problem]

(i) When an elastic fiber and an inelastic fiber in a composite elasticyarn are both polyolefin-based fibers, such a composite elastic yarn ishighly resistant to chemicals and weathering. A cross-linkedpolyolefin-based fiber is preferably employed as such an elastic fiber.

(ii) When the inelastic fiber in such a composite elastic yarn is forexample a high-tenacity polyethylene filament, a composite elastic yarnwith extremely high tenacity is provided. A glove made of a fabriccomprising such a composite elastic yarn ensures a comfortable fit anddemonstrates excellent cut resistance, chemical resistance, and weatherresistance. Furthermore, a glove manufactured using such a compositeyarn has quick-drying properties.

-   -   (iii) When a fabric is obtained by weaving or knitting a        composite elastic yarn made of an elastic yarn comprising a        cross-linked polyolefin fiber and an inelastic yarn not        comprising any polyolefin fiber, because cross-linked polyolefin        fibers are highly resistant to chemicals, a watermark-like        pattern can be formed on such a fabric by dissolving the        inelastic yarn by opal finishing.

The present invention has been accomplished based on these findings, andprovides composite elastic yarns and so forth as described below.

-   -   Item 1. A composite elastic yarn comprising a polyolefin-based        elastic fiber and a polyolefin-based inelastic fiber.    -   Item 2. A composite elastic yarn according to Item 1, wherein        the polyolefin-based elastic fiber is a cross-linked        polyolefin-based elastic fiber.    -   Item 3. A composite elastic yarn according to Item 1, wherein        the polyolefin-based inelastic fiber is a high-molecular-weight        polyethylene fiber having a weight average molecular weight of        at least 10×10⁵.    -   Item 4. A composite elastic yarn according to Item 3, wherein        the high-molecular-weight polyethylene fiber is a high tenacity        multifilament fiber with a tenacity of 20 cN/dtex or more and an        resistance of incipient tension of 200 cN/dtex or more.    -   Item 5. A composite elastic yarn according to Item 1, comprising        1 to 50 wt. % of the polyolefin-based elastic fiber.    -   Item 6. A composite elastic yarn according to Item 1, which is a        covered yarn formed by covering the polyolefin-based elastic        fiber with the polyolefin-based inelastic fiber.    -   Item 7. A glove partially or wholly composed of a woven fabric        or knitted fabric comprising the composite elastic yarn of Item        1.    -   Item 8. A glove according to Item 7, wherein a portion        comprising the composite elastic yarn of Item 1 contains at        least 30 wt. % of the composite elastic yarn.    -   Item 9. A method for manufacturing a glove, comprising weaving        or knitting the composite elastic yarn of Item 1.    -   Item 10. Use of the composite elastic yarn of Item 1 as a        material for gloves.    -   Item 11. Use of the composite elastic yarn of Item 1 for        manufacturing gloves.    -   Item 12. A stretchable fabric with a watermark-like pattern, the        stretchable fabric comprising a cross-linked polyolefin-based        elastic fiber and an inelastic fiber, and having a        watermark-like pattern produced by complete or incomplete        removal of the inelastic fiber with partial burn-out printing.    -   Item 13. A stretchable fabric according to Item 12, wherein the        inelastic fiber is at least one kind of natural fiber selected        from the group consisting of cotton fibers, hemp fibers, kenaf        fibers, natto(fermented soybean) fibers, soy protein fibers,        wool fibers, silk fibers, cashmere fibers, and mohair fibers.    -   Item 14. A stretchable fabric according to Item 12, wherein the        inelastic fiber is at least one kind of chemical fiber selected        from the group consisting of rayon fibers, cuprammonium rayon        fibers, acetate fibers, promix fibers, polylactic acid fibers,        polyester-based fibers, polyamide-based fibers, polyolefin-based        fibers, and acrylic fibers.    -   Item 15. A stretchable fabric according to Item 12, wherein the        inelastic fiber comprises at least one kind of natural fiber        selected from the group consisting of cotton fibers, hemp        fibers, kenaf fibers, fermented soybean fibers, soy protein        fibers, wool fibers, silk fibers, cashmere fibers, and mohair        fibers; and at least one kind of chemical fiber selected from        the group consisting of rayon fibers, cuprammonium rayon fibers,        acetate fibers, promix fibers, polylactic acid fibers,        polyester-based fibers, polyamide-based fibers, polyolefin-based        fibers, and acrylic fibers.    -   Item 16. A stretchable fabric according to Item 12, wherein the        burn-out printing is opal finishing.    -   Item 17. A stretchable fabric according to Item 12, comprising 3        to 20 wt. % of the cross-linked polyolefin-based elastic fiber.    -   Item 18. A method for manufacturing a stretchable fabric with a        watermark-like pattern, comprising applying partial burn-out        printing to a fabric comprising a cross-linked polyolefin-based        elastic fiber and an inelastic fiber, thereby completely or        partially removing the inelastic fiber of a processed portion of        the fabric to make a watermark-like pattern.

In the composite elastic yarn of the present invention, apolyolefin-based fiber is employed for elastic and inelastic fibers, andaccordingly, excellent chemical resistance and weatherability areprovided. Furthermore, when, for example, a high-molecular-weightpolyethylene fiber or like high tenacity fibers are used as an inelasticfiber, the resulting composite yarn as a whole has extremely hightenacity.

The composite elastic yarn of the present invention is thus especiallysuitable as a material for gloves that are used for handling sharp-edgedtools or like activities that might cause injuries. Materialsconventionally employed for cut-resistant gloves include aramid fibers,metal fibers, glass fibers and the like. However, gloves produced withthese materials have problems such as difficulties in knitting,inconveniences caused by conductivity, and the danger that fibers mightbreak and pierce the hand. In this regard, gloves produced from thecomposite elastic yarn of the present invention are advantageous as thefibers therein have excellent flexibility which leads to an ease inknitting, possess electrical insulating properties, and do not easilybreak.

Furthermore, the present invention provides a stretchable fabric havinga watermark-like pattern thereon, which has not been achieved before.More specifically, the stretchable fabric of the invention comprises anelastic fiber and an inelastic fiber, and the elastic fiber is across-linked polyolefin-based fiber which is highly resistant tochemicals; due to such a structure, the watermark-like pattern is formedthereon by destroying the inelastic fibers with a burn-out printingmethod. Unlike urethane-based elastic fibers, cross-linkedpolyolefin-based fibers do not yellow easily, and thus a watermark-likedesign with high transparency can be maintained over long-term use. Thestretchable fabric of the invention is of beautiful appearance and hasexcellent stretchability, and hence is suitable for a wide range ofuses, including applications to underwear and sportswear.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will be described in more detail hereinafter.

(I) Composite Elastic Yarn

The composite elastic yarn of the present invention comprises apolyolefin-based elastic fiber and a polyolefin-based inelastic fiber.

As polyolefin-based fibers are highly resistant to chemicals andweathering, fabrics obtained by weaving or knitting the compositeelastic yarn of the invention do not easily discolor, and furthermore,the initial fabric properties can be maintained even under harshconditions, such as exposure to outdoor conditions or to industrialcleaning using chemicals. Moreover, because polyolefin-based fibers havelow densities, a stretchable fabric obtained therefrom is lightweighteven when thick. Furthermore, as polyolefins are hydrophobic materials,the composite elastic yarn and stretchable fabric comprising the same ofthe invention allow quick and easy drying.

Although the form of the composite elastic yarn of the invention is notlimited, in terms of cut resistance of the resulting fabric, a coveredyarn wherein an elastic fiber is uniformly covered with an inelasticfiber is preferable. Such a covered yarn can be manufactured with acovering machine, or alternatively, it may also be produced by draftingan elastic yarn and at the same time plying and twisting it with aninelastic fiber.

The proportion of elastic fiber in the composite elastic yarn of thepresent invention is usually 1 wt. % or more, preferably 5 wt. % ormore, and more preferably 10 wt. % or more. The upper limit of theproportion of elastic fiber is usually 50 wt. % or less, and preferably30 wt. % or less. The specified range can achieve sufficientstretchability and recoverability, along with practically sufficienttenacity.

An “elastic fiber” as used herein signifies a fiber having an elasticitygenerally accepted as being rubber elasticity, such as, for example, afiber wherein, after 50% elongation is applied (i.e., when stretched to1.5 times), at least 50% of the elongation is recovered.

Examples of such polyolefin-based elastic fibers include cross-linkedpolyolefin-based elastic fibers. Cross-linked polyolefins are obtainableby cross-linking of substantially linear olefins, and their branchpoints are substantially uniformly distributed over the main chain. Suchcross-linked polyolefins can be produced by chemical cross-linking usingradical initiators, coupling agents and/or the like, afterpolymerization of olefin-based monomers. Cross-linking may also beformed, after polymerization, by irradiation of energetic beams such aselectron beams, β-rays, and γ-rays. Considering the stability of the endproducts, cross-linking by energetic beam irradiation is preferable.

A desirable degree of cross-linking is such that, for example, thexylene extract measured according to ASTM D-2765 is 70 wt. % or less(i.e., a gel content of 30 wt. % or more), and preferably 40 wt. % orless (i.e., a gel content of 60 wt. % or more).

Ethylene can be mentioned as an example olefin.

Specific examples of cross-linked polyolefins include cross-linked lowdensity polyethylenes in which an α-olefin has been copolymerized, andthe cross-linked polyolefins disclosed in JP 2002-515530 A.

Due to their cross-linked structure, cross-linked polyolefin-basedelastic fibers have excellent stretchability, chemical resistance,weatherability, and heat resistance.

In the present invention, an “inelastic fiber” indicates a fiber withoutso-called rubber elasticity, such as polyesters, polyamides,polyethylenes, polypropylenes, and other known fibers which do notrecover from elongation. Examples thereof include fibers wherein, when50% elongation is applied (i.e., when stretched to 1.5 times), less than50% of the elongation is recovered.

Usable inelastic fibers are, for example, fibers made ofhigh-molecular-weight polyethylene having a weight average molecularweight of 1×10⁶ or more. The polyethylene fiber or filament ispreferably a filament with high tenacity and high elasticity, andespecially preferable thereof is a high-tenacity multifilament having atenacity of at least 20 cN/dtex and a resistance of incipient tension ofat least 200 cN/dtex, since a glove made of such a multifilament hasexcellent cut resistance. In addition, high-tenacity and high-elasticpolyethylene filaments have low surface friction coefficients and theirabrasion resistance is thus excellent. Therefore, when employed as aglove material, lightness together with a comfortable fit can beachieved.

The tenacity and resistance of incipient tension of a polyethylenefilament are measured according to the methods described in theExamples.

When materials etc. for the composite elastic yarn of the presentinvention are suitably selected from the above-specified ranges, thechemical resistance of the resulting yarn is such that the strengthretention therein after chlorine treatment is 85% or more, andpreferably 90% or more. The conditions for chlorine treatment and themeasuring method for strength retention are as shown in the Examples.The durability of a fabric with such strength retention is practicallysufficient to endure cleaning under harsh conditions, chlorinesterilization, and the like.

When materials etc. are suitably selected from the above-specifiedranges, the composite elastic yarn of the present invention providesweatherability such that yellowing (Δb value) after light irradiation is5% or less, preferably 3% or less, and more preferably 1% or less. Themethod of evaluating yellowing is as described in the Examples. Yarnswith such a Δb value are not likely to yellow even when used in harshconditions, such as longtime outdoor exposure.

(II) Glove

Due to its excellent stretchability, the above-described compositeelastic yarn of the present invention is suitable as a material forgloves. A use of the present invention is thus the use of the compositeelastic yarn of the invention as a glove material.

The glove of the present invention is partially or entirely composed ofa woven or knitted fabric comprising the above-described compositeelastic yarn of the invention.

The cut-resistant glove of the present invention can be obtained byknitting yarns including the composite elastic yarn of the invention. Itmay also be manufactured by cutting and sewing a fabric obtained byweaving the composite elastic yarn of the present invention.

The glove of the present invention may contain, in addition to thecomposite elastic yarn of the invention, synthetic fibers such aspolyesters, nylons, and acrylics; natural fibers such as cotton andanimal hair; and regenerated fibers such as rayon. The fibers in thefabric may be in the form of filaments or spun yarns.

In order to achieve high resistance to abrasion, about 1- to about4-dtex polyester multifilaments and similar nylon filaments arepreferable. Polypropylene filaments are especially preferable due totheir high lightfastness, excellent chemical resistance and low specificgravity.

The proportion of composite elastic yarn is usually at least 30 wt. % ofall the yarns used in the glove, preferably at least 50 wt. %, and morepreferably at least 70 wt. %. Such a proportion provides sufficient cutresistance as is required in a glove for injury-prone activitiesinvolving glass, knives and the like.

The thus-obtained glove is usable as is. If necessary, a urethane-basedresin or ethylene-based resin may be applied thereto for the purpose ofproviding non-slip performance.

(III) Stretchable Fabric with a Watermark-Like Pattern

The stretchable fabric with a watermark-like pattern of the presentinvention comprises a cross-linked polyolefin-based elastic fiber and aninelastic fiber, on which a watermark-like design is provided bycomplete or incomplete removal of the inelastic fiber with partialburn-out printing.

The definition of elastic fiber is as given above. The cross-linkedpolyolefin-based elastic fiber is also as described above.

The definition of inelastic fiber is also as above. The kind ofinelastic fiber is not limited as long as it is destroyable by aburn-out printing process which does not destroy cross-linkedpolyolefin-based elastic fibers. Such an inelastic fiber may be anatural fiber, chemical fiber, or a combination thereof.

Examples of natural fibers include cotton fibers, hemp fibers, kenaffibers, fermented-soybean fibers, soy protein fibers, wool fibers, silkfibers, cashmere fibers, mohair fibers and the like. Cotton fibers, silkfibers, wool fibers, soy protein fibers and the like are preferablyemployed for a natural inelastic yarn, as these fibers achieve a finehand and texture and high moisture absorbency. Cottons fibers, silkfibers and the like are especially preferable.

Examples of chemical fibers include rayon fibers, cuprammonium rayonfibers, acetate fibers, promix fibers, polylactic acid fibers,polyester-based fibers, polyamide-based fibers, polyolefin-based fibers,vinylon-based fibers, acrylic fibers and the like. Polylactic acidfibers, polyester-based fibers, polyamide-based fibers and the like arepreferably selected as a chemical inelastic fiber, due to theirexcellent solubility. Polyester-based fibers and polylactic acid fibersare especially preferable.

Such inelastic fibers can be used singly or as a combination of two ormore kinds. In order to obtain a fabric which combines practicality anda beautiful appearance, it is preferable to use an inelastic yarn,wherein a natural fiber which generally has low acid resistance and achemical fiber which generally has high acid resistance are combined inthe form of a co-twisted yarn, filament mixed yarn, composite spun yarnor covered yarn. With such a structure, it is possible to selectivelyremove natural fibers by the application of sulfuric acid or the like.Not only cross-linked polyethylene elastic fibers but also otherchemical fibers are left undestroyed, whereby beautiful watermark-likepatterns can be achieved. Particularly suitable combinations are cottonor silk natural fibers with polyester-based or polylactic acid chemicalfibers.

Such an inelastic fiber is served to a cross-linked polyolefin-basedelastic fiber to weave or knit. The method for combining elastic andinelastic fibers is not limited; examples of usable fabrics includeunion fabric, union knit, examples of usable yarns include co-twistedyarns, filament mixed yarns, composite spun yarns, covered compositeyarns, and the like. A covered yarn wherein a cross-linkedpolyolefin-based elastic fiber is covered with an inelastic fiber ispreferably employed. Because the elastic fiber is almost completelycovered with the inelastic fiber in such a covered yarn, a fabricobtained by weaving or knitting this yarn is a high-tenacity fabric witha pleasant hand and texture.

The role of an elastic fiber in a fabric is to provide stretchability,and the proportion of elastic fiber in the fabric is preferably 20 wt. %or less, and more preferably 15 wt. % or less. The lower limit ispreferably at least 3 wt. %, and more preferably at least 5 wt. %. Whenelastic fibers are used in such a range, the resulting product does nothave a plastic-like hand and texture, as is particular to elastic yarns.Furthermore, the surface of such a fabric is smooth. Moreover, as theelastic fiber is unlikely to be exposed at the fabric surface, thefabric has no irritatingly glossy appearance. The above-specified rangeis also advantageous because these fibers are expensive. Use of anelastic fiber within such a range can achieve practically sufficientstretchability in a resulting fabric.

The fabric of the invention contains a cross-linked polyolefin-basedelastic fiber, and thus has good stretchability. The elongation of thefabric under constant load in the direction of the extension of theelastic fiber is preferably 10% or more, and the recovery therefrom ispreferably 60% or more. It is more preferable that the elongation underconstant load be 15% or more and the recovery be 70% or more. Such arange leads to a fabric having practically sufficient stretchability.Moreover, when a fabric with such a range is made into various shapesand affixed to something, a sufficient flexibility is assured. Althoughno upper limit to elongation under constant load is given, a limit ofabout 900% is usually preferable in terms of handleability. Methods formeasuring elongation under constant load and recovery therefrom are asindicated in the Examples. When the warp yarns and weft yarns are bothmade of elastic fibers, the term “elongation under constant load”signifies the mean of the elongations under constant load in bothdirections.

Such stretchability can be attained by suitably selecting the kinds ofelastic and inelastic fibers, and the proportions thereof in a fabricwithin the above-given ranges.

Portions of the fabric of the present invention have a watermark-likedesign. The watermark-like design is formed by completely orincompletely removing the inelastic fiber by burn-out printing. In otherwords, the method of the present invention for manufacturing astretchable fabric with a watermark-like pattern is a method which formsa watermark-like pattern on a fabric comprising a cross-linkedpolyolefin-based fiber and an inelastic fiber by partially, completely,or incompletely destroying the inelastic fiber.

Opal-finishing can be mentioned as an example of a method for burn-outprinting. This method comprises the steps of printing a fabric with apaste containing sulfuric acid; aluminium sulfate; sodium sulfate; oneor more alkaline metal hydroxides, carbonates, and/or bicarbonates;and/or sodium hydroxide, and applying heat to the printed fabric toremove inelastic fibers which have inferior chemical resistance.

The stretchable fabric of the present invention can be obtained byapplying partial burn-out printing to a fabric comprising a cross-linkedpolyolefin-based elastic fiber and an inelastic fiber, and completely orincompletely removing the inelastic fiber therein, thereby forming awatermark-like design on the fabric.

EXAMPLES

The following examples illustrate the present invention in furtherdetail, but the scope of the invention is not limited by these examples.

(I) Example of Glove Production Using Composite Elastic Yarn.

<Evaluation of Chlorine Resistance Ability>

The evaluation was conducted using a testing device as disclosed in JP2000-97933 A for evaluating chlorine resistance of a swimsuit. Thedevice comprises:

-   -   (1) a water tank for immersion of a test sample; a        sample-holding means to hold the sample; a buffer tank for        measuring the chlorine concentration and pH of the solution        contained in the water tank; an adjustment tank for adjusting        the chlorine concentration and pH of the solution in the water        tank; and a controlling system for adjusting the chlorine        concentration and pH of the solution in the water tank to a set        value, based on the measured values of chlorine concentration        and pH; wherein    -   the chlorine concentration and pH of a solution are adjusted to        a set value in the adjustment tank by the controlling system,        and the solution is then circulated in the water tank; and the        device further comprising:    -   (2) a water temperature-controlling system for adjusting the        solution temperature in the water tank to a set value; and        wherein    -   (3) the sample-holding means is supported by a sample-moving        means, and is movable at a constant speed in relation to the        solution in the water tank; and    -   (4) the sample-holding means is supported by a swimsuit-moving        means whose installation angle to the water flow is variable.

Using this testing device, changes in pH of a chlorine solution due toimmersion of a sample therein are suppressed, and conditions in thewater tank wherein the sample is immersed are uniformly maintained.Furthermore, the swimsuit sample receives a water stream, which modelsthe situation of swimming. As a result, measurements at conditionssimilar to real-life dynamic situations can be made, whereby a practicalchlorine resistance evaluation is possible.

1) Preparation of Sodium Hypochlorite Solution

50 ml of sodium hypochlorite (antiformin: manufactured by NacalaiTesque, Inc.) was obtained, and pure water was added thereto to make thewhole quantity 5 l.

2) Preparation of Acetic Acid Solution

50 ml of acetic acid (manufactured by Nacalai Tesque, Inc.) wasobtained, and pure water was added thereto to make the whole quantity 5l.

3) Installation of Specimen

Using the composite elastic yarn, a tubular-knitted fabric specimen wasobtained, and fixed in an unstretched state with a pin line on a framemade of stainless steel.

4) Test Conditions

The test conditions are as follows.

-   Effective chlorine concentration: 3.0 ppm-   pH: 7.5-   Temperature: 30° C.-   Fabric rotation speed: 17.6 rad/s-   Fabric installation position: 50 cm away from the rotation axis    (Rotating with the above rotation speed at the above installation    position, the specimen receives a water stream at a rate of about    1.4 m/s)-   Current angle to the fabric: 90°-   Operating (rotation) conditions: intermittent operation with 10    seconds of operation and 10 seconds of stoppage-   Operating time: 288 hours

The processed sample was fully washed with water and dried at a roomtemperature.

<Measurement of Strength Retention>

A plain-knitted fabric was manufactured by knitting a composite elasticyarn with a 16-guage tubular knitting machine having a diameter of 3.5inches. The obtained fabric was processed for 30 minutes with boilingwater, and then subjected to a severe test pursuant to test methods forcolor fastness to bleaching with hypoclorite defined in JIS-L-0856(2002) (sodium hypochlorite solution A). After drying the specimen, thecomposite elastic yarns therein were raveled out, and elastic yarns weretaken out therefrom and then subjected to an S-S test to measure thebreaking tenacity (d2).

For a product evaluation, a product was first raveled out to take outthe composite elastic yarns, and the elastic yarns were separatedtherefrom and subjected to an S-S test (d1). Separately, a similarproduct was treated with chlorine in the same manner as above, andelastic yarns were isolated after raveling out of the product, an S-Stest carried out, and the breaking tenacity measured (d2). Strengthretention (%) was calculated using the formula [(d2)/(d1)]×100.

<Evaluation of Lightfastness>

Using a high-energy sunshine fade meter (carbon arc) manufactured bySuga Test Instruments Co., Ltd., light irradiation treatment was appliedto a tubular-knitted fabric made of a composite elastic yarn under thefollowing conditions.

-   -   Temperature: 90° C.    -   Irradiation time: 90 hours        Next, using a SPECTROPHOTOMETER CM-3700d manufactured by        MINOLTA, the degree of discoloration was evaluated using the Δb        value.

-   Δb=b1−b2    -   b1: b value of the fabric prior to light irradiation    -   b2: b value of the fabric after light irradiation        <Evaluation of Quick-Drying Properties>

Glove samples were placed in tap water for 10 minutes, and spin-driedwith a domestic washing machine for 5 minutes. Three monitors wore theprocessed gloves and evaluated their degree of comfort.

<The Method of Measuring Tenacity and Resistance of Incipient Tension>

Tenacity and elastic modulus were measured as follows. Using a Tensilonmanufactured by Orientec Co., Ltd., a specimen of 200 mm (length betweenchucks) was stretched at the rate of 100% elongation/minute. While thespecimen was being stretched, the stress thereof was measured at anatmosphere temperature of 20° C. and a relative humidity of 65%, and astrain-stress curve was thereby obtained. The stress at the breakingpoint was defined as tenacity (cN/dtex). Elastic modulus was calculatedfrom the tangent of the maximum slope, near the origin of the curve. 10measurements were taken, and the mean value thereof was employed.

Example 1-1

A yarn made of a 70-dtex monofilament manufactured by melt-spinning anα-olefin-copolymerized polyethylene was cross-linked using an electronbeam, obtaining a cross-linked polyolefin fiber (herein after referredto as fiber (A)) (product name: DOWXLA, manufactured by Toyobo Co.,Ltd.). Two specimens of the obtained fiber (A) were put together,drafted to 1.55 times, and plied and twisted together with a 440-dtexmultifilament fiber (herein after referred to as fiber (B)), which is anultra-high-molecular-weight polyethylene fiber (product name: SK60,manufactured by Toyobo Co., Ltd.) having a tensile strength of 27cN/dtex and a resistance of incipient tension of 900 cN/dtex, to obtaina composite elastic yarn (herein after referred to as fiber (X)) whereinthe number of twists was 200 T/M. A glove was manufactured with afashioning stitch machine using only the obtained composite elasticyarn.

Example 1-2

Using one specimen of fiber (A) instead of two, a composite elastic yarn(herein after referred to as fiber (Y)) was obtained in otherwise thesame manner as in Example 1-1. Using a fashioning stitch machine, yarn(Y) was knitted with a polypropylene fiber-processed yarn having 84dtex, 36 filaments, and a glove thereby obtained.

Example 1-3

Using a nylon filament yarn having 77 dtex, 24 filaments instead of thepolypropylene fiber-processed yarn, a glove was manufactured inotherwise the same manner as in Example 1-2. Wet coating with a urethaneresin was applied to the palm side of the obtained glove.

Comparative Example 1-1

Using an 88-dtex polyurethane-urea elastic fiber (product name: ESPA,manufactured by Toyobo Co., Ltd.;) instead of fiber (A), a glove wasproduced in otherwise the same manner as in Example 1-1. Because of thehigh density of the elastic yarn, the obtained composite elastic yarnlacked lightness, and furthermore, it was poor in chlorine resistanceand lightfastness.

Comparative Example 1-2

Using an aramid fiber in place of fiber (B), a glove was produced inotherwise the same manner as in Example 1-1. The obtained compositeelastic yarn easily discolored, and its lightfastness was poor.

The results of the evaluation of the gloves obtained in the aboveexamples are shown in Table 1 below. TABLE 1 Ex. 1-1 Ex. 1-2 Ex. 1-3Comp. Ex. 1-1 Comp. Ex. 1-2 Elastic fiber (dtex) Ethylene-basedEthylene-based Ethylene-based Urethane-based Ethylene-based 140 70 70 88140 Inelastic fiber Polyethylene Polyethylene Polyethylene PolyethyleneAramid (dtex) 440 440 440 440 440 fiber for union — Polypropylene Nylon— — knit(dtex) 84 77 Proportion of 100 85 86 100 100 composite elasticyarn (%) Discoloration Δ d 1 1 3 10 15 Strength retention 95 95 95 47 95(%) Quick-drying Excellent Excellent Fair Good Fair properties Overallevaluation Excellent Excellent Good Poor Poor(II) Production Example for Stretchable Fabric with Watermark-LikePattern<Elongation under Constant Load and Recovery Therefrom>

A fabric was tested for elongation in the warp and weft directions underconstant load and for recovery therefrom, in accordance with the methodsdescribed in “Fuai hyoka no hyojunnka to kaiseki [Standardization andanalysis of textures]” (edited by The Textile Machinery Society ofJapan), chapter IV, “Nuno no rikigakuteki tokusei no sokutei[Measurement of dynamic characteristics of a fabric]”. Specimens havinga width of 20 cm and a length of 5 cm were taken from a fabric both inthe warp and weft directions and stretched in the lengthwise directionat a constant rate of 4.00×10⁻³ m/sec to a maximum load of 100 gf/cm.The elongation at the maximum load was measured. The stretched specimensthen underwent a deformation recovering process. The elongation recoverywas defined as the ratio of [the difference between the degree ofelongation and the degree of deformation at zero stress after thedeformation recovery] relative to [the degree of elongation]. In case ofa tubular-knitted fabric, the course direction was employed. For a wovenfabric, elongation and recovery in the direction in which the elasticyarn was stretched (when stretched both in the warp and weft directions,the mean value of the two) were observed.

Example 2-1

A plane knitted fabric was obtained by knitting, using a plane knittingmachine, a 44-dtex cross-linked polyolefin-based elastic yarn (productname: DOWXLA, manufactured by of Toyobo Co., Ltd.) with a composite spunyarn of 60 cotton yarn count comprising a polyester fiber having 56dtex, 68 filaments and a cotton yarn of 100's, and cut at the center.Using a screen printing machine (product name: ICHINOSE #7000-type,manufactured by Toshin Kogyo Co., Ltd.), a preliminary floral patternwas printed on the obtained fabric, and a sulfate-containing paste wasapplied to the patterned portion. The fabric was then heat-treated at105° C. for 2 minutes with a heater, steam-treated at 130° C. for 30minutes, washed with water, and dried. Due to this operation, cottonfibers which are poorly acid resistant were selectively dissolved andremoved, thereby giving a plain knitted fabric featuring a clear floralwatermark-like design.

Elongation and elongation recovery of the obtained knitted fabric were54% and 85%, respectively.

Example 2-2

The procedure of Example 2-1 was followed, except that a vinylon fiberhaving 44 dtex, filaments was used instead of the polyester fiber. As inExample 2-1, the cotton fiber was dissolved and removed, and aplain-knitted fabric provided with a beautiful floral watermark-likedesign was obtained. Elongation and elongation recovery of thisknitted-fabric were 62% and 81%, respectively.

Comparative Example 2-1

The procedure of Example 2-1 was repeated, except for using a 44-dtexpolyurethane elastic yarn (product name: ESPA 465, manufactured byToyobo Co., Ltd.) instead of the 44-dtex cross-linked polyolefin-basedelastic yarn. The polyurethane elastic fiber was dissolved by acid, andonly the polyester fiber was left in the fabric. As a result, the fabriccontained holes, and no floral watermark-like pattern was formedthereon. The elongation of this fabric was 53%, whereas elongationrecovery was low, at 42%.

The composite elastic yarn of the present invention exhibits excellentchemical resistance and high lightfastness, and is thus suitable forapplication to swimsuits, underwear, outerwear, diaper covers, sanitaryproducts, tents and like outdoor products, industrial materials and thelike.

When using high-tenacity fibers as inelastic fibers, the obtained yarnsare suitable as a material for gloves for use in dangerous work such ashandling iron plates with sharp edges or burrs, dealing with glass, andin dangerous work using knives, such as the processing of meat andcutting of large fish.

Moreover, as the stretchable fabric of the present invention features abeautiful appearance with a watermark-like pattern in addition to theexcellent stretchability, it is suitable as a material for underwear andsportswear.

1. A composite elastic yarn comprising a polyolefin-based elastic fiberand a polyolefin-based inelastic fiber.
 2. A composite elastic yarnaccording to claim 1, wherein the polyolefin-based elastic fiber is across-linked polyolefin-based elastic fiber.
 3. A composite elastic yarnaccording to claim 1, wherein the polyolefin-based inelastic fiber is ahigh-molecular-weight polyethylene fiber having a weight averagemolecular weight of at least 10×10⁵.
 4. A composite elastic yarnaccording to claim 3, wherein the high-molecular-weight polyethylenefiber is a high tenacity multifilament fiber with a tenacity of 20cN/dtex or more and a resistance of incipient tension of 200 cN/dtex ormore.
 5. A composite elastic yarn according to claim 1, comprising 1 to50 wt. % of the polyolefin-based elastic fiber.
 6. A composite elasticyarn according to claim 1, which is a covered yarn formed by coveringthe polyolefin-based elastic fiber with the polyolefin-based inelasticfiber.
 7. A glove partially or wholly composed of a woven fabric orknitted fabric comprising the composite elastic yarn of claim
 1. 8. Aglove according to claim 7, wherein a portion comprising the compositeelastic yarn of claim 1 contains at least 30 wt. % of the compositeelastic yarn.
 9. A method for manufacturing a glove, comprising weavingor knitting the composite elastic yarn of claim
 1. 10. (canceled)
 11. Astretchable fabric with a watermark-like pattern, the stretchable fabriccomprising a cross-linked polyolefin-based elastic fiber and aninelastic fiber, and having a watermark-like pattern produced bycomplete or incomplete removal of the inelastic fiber with partialburn-out printing.
 12. A stretchable fabric according to claim 11,wherein the inelastic fiber is at least one kind of natural fiberselected from the group consisting of cotton fibers, hemp fibers, kenaffibers, fermented soybean fibers, soy protein fibers, wool fibers, silkfibers, cashmere fibers, and mohair fibers.
 13. A stretchable fabricaccording to claim 11, wherein the inelastic fiber is at least one kindof chemical fiber selected from the group consisting of rayon fibers,cuprammonium rayon fibers, acetate fibers, promix fibers, polylacticacid fibers, polyester-based fibers, polyamide-based fibers,polyolefin-based fibers, and acrylic fibers.
 14. A stretchable fabricaccording to claim 11, wherein the inelastic fiber comprises at leastone kind of natural fiber selected from the group consisting of cottonfibers, hemp fibers, kenaf fibers, fermented soybean fibers, soy proteinfibers, wool fibers, silk fibers, cashmere fibers, and mohair fibers;and at least one kind of chemical fiber selected from the groupconsisting of rayon fibers, cuprammonium rayon fibers, acetate fibers,promix fibers, polylactic acid fibers, polyester-based fibers,polyamide-based fibers, polyolefin-based fibers, and acrylic fibers. 15.A stretchable fabric according to claim 11, wherein the burn-outprinting is opal finishing.
 16. A stretchable fabric according to claim11, comprising 3 to 20 wt. % of the cross-linked polyolefin-basedelastic fiber.
 17. A method for manufacturing a stretchable fabric witha watermark-like pattern, comprising applying partial burn-out printingto a fabric comprising a cross-linked polyolefin-based elastic fiber andan inelastic fiber, thereby completely or partially removing theinelastic fiber of a processed portion of the fabric to make awatermark-like pattern.